Heavy-duty hydraulic tube end forming machine with automatically operated chuck, punch, and stop means



Feb. 27, 1951 J. L. VAlLL HEAVY-DUTY HYDRAULIC TUBE END FORMING MACHINEWITH AUTOMATICALLY OPERATED CHUCK, PUNCH, AND STOP MEANS Filed July 30,1945 Y.

5 Sheets-Sheet l INVENTOR. Jfi/v. 144/44 J. L. VAIL HEAVY-DUTY HYDRAULICTUBE END FORMING MACHINE WITH AUTOMATICALLY OPERATED CHUCK, PUNCH, ANDSTOP MEANS Filed July 50, 1945 5 Sheets-Sheet 2 Feb. 27, 1951 2,543,480

I IN V EN TOR. Jmv A. Z444 Feb. 27, 1951 J. 1.. VAILL 2,543,480

HEAVY-DUTY HYDRAULIC TUBE END FORMING MACHINE WITH AUTOMATICALLYOPERATED CHUCK, PUNCH, AND STOP MEANS Filed July so, 1945 s Sheets$heet3 INVENTOR. JH/VA. 1/4/41.

1951 J. L. VAILL HEAVY-DUTY HYDRAULIC TUBE END FORMING MACHINE WITHAUTOMATICALLY OPERATED cnucx, PUNCH, AND STOP MEANS Filed July 30, 19455 Sheets-Sheet 4 IN V EN TOR.

Feb. 27, 1951 J. 1.. VAILL 2,543,430

HEAVY-DUTY HYDRAULIC TUBE END FORMING MACHINE WITH AUTOMATICALLYOPERATED CHUCK, PUNCH, AND STOP MEANS Filed July 30, 1945 5 Sheets-Sheet5 v j I J "33a, 30

75 i 1 it 29 ll id ii 1 i! IL I I I f i fin; 1 i I TH" 56 .37

' INVENTOR. L7/m Z. M441.

AT 7 @5125 'Y Patented F eb. 27, 1951 HEAVY-DUTY HYDRAULIC TUBE ENDFORM- ING MACHINE WITH AUTOMATICALLY OPERATED CHUCK, PUNCH, AND STOPMEANS John L. Vaill, Waterbury, Conn.

Application July 30, 1945, Serial No. 607,758

6 Claims. 1

This invention relates to tube end forming machines, and moreparticularly to a manuallycontrolled hydraulically-operated machine forautomatically beading, flaring, fianging, expanding, sinking, andotherwise shaping the end of a tube of any workable material, such asaluminum, steel, etc.

One object of the present invention is to provide a machine of the abovenature, in which the tube will be manually inserted and pushed againstan adjustable stop member and then clamped by means of a pair ofcooperating chucking die members before the shaping or formingoperation.

A further object is to provide a machine of the above nature, in whichthe stop member will be swung downwardly out of the way of the formingtool before the latter strikes the end of the tube.

A further object is to provide a machine of the above nature in whichthe stop member is pivotally connected to the upper crosshead of themachine, and is movable with it downwardly out of the way of the formingtool before the latter strikes the end of the tube.

A further object is to provide a machine of the above nature having asplit horizontal chucking die, the upper section of which is movabledownwardly by hydraulic action for clamping the work tightly against thelower section prior to and during the forming operation.

A further object is to provide a machine of the above nature in whichprovision is made of a set of interchangeable dies and punches, whichwill permit a wide variety of tube sizes and shapes to be formed on asingle machine.

A further object is to provide a machine of the above nature in whichsinking and expanding tools may also be selectively carried by the sameram which operates the beading, flaring, and fianging punch.

A further object is to provide a machine of the above nature, in whichthe tube end forming operation will be performed automatically in afraction of the time required with former manual methods, and whichmachine may be operated by relatively unskilled labor on a massproduction basis.

A further object is to provide a machine of the above nature which willbe relatively simple in construction, inexpensive to manufacture, easyto install and manipulate, compact, ornamental in appearance, safe andquiet in operation, powerful, double-acting, self-lubricated, having 'a,minimum of moving parts, and very efiicient and durable in use.

embodying the present invention.

Fig. '2 is a rear elevation of the same, showing the arrangement of theoperating valves and piping connections.

Fig. 3 is a top plan view Of the same, showing a flaring punch holdersecured on the forward end of the reciprocating ram.

Fig. 4 is a perspective view, on a larger scale,

of one half of the split tube-chucking die.

Fig. 5 is a side view, partly in section, of a flared tube produced bythe machine.

Fig. 6 is a longitudinal sectional view of the machine, taken along theline 66 of Fig. 3, looking in the direction of the arrows.

Fig. 6A is a fragmentary sectional view similar to a portion of Fig. 6,showing the die, the punch, and the stop bar in the positions they would00- cupy at the end of a flaring operation, and also showing the flaredtube partly in section.

Fig. 7 is a, transverse sectional view taken along the line 1-! of Fig.6.

Fig. 8 is a perspective view of an intermediate sinking die which isadapted to be detachably connected to the tool-carrying ram and which isinterchangeable with the forward tube end forming punch holder.

Fig. 8a is a fragmentary sectional view showing the appearance of thesinking die when installed in operating position in the opposed slots ofthe ram.

Fig. 9 is a fragmentary sectional view of the forward part of the ram,showing the expanding punch installed at the rear of the ram recess.

The heavy duty hydraulic tube end forming machine herein disclosed issimilar in some respects, and constitutes an improvement over a lightweight pneumatically-operated tube end forming machine, disclosed in aprior application by the same inventor, Serial No. 556,189, filedSeptember 28, 1944, and entitled Tube End Forming Machine, patented May25, 1948, No. 2,442,224.

In the cycle of operation of the present machine, when the start pushbutton is pressed, the crosshead will first move down to close thechucking dies about the tube, which has previously been insertedmanually through said dies. The horizontal ram (carrying the formingtool or tools) will then move forwardly to process the tube end shape,and then withdraw-each phase of the operating cycle progressingautomatically without further attention on the part of the operator. Theupper chucking die will then rise to permit the manual removal of theformed tube.

The present machine employs the cold forging principle. A steadyhydraulic pressure is exerted on the full circumference of the tube end,with the result that more severe and complete working of the metalbecomes possible than could be accomplished with any rolling or spinningprocess where only a small section of the tube was engaged at one time.

During the forming operation, the gauge may actually be increased,resulting in greater strength, and smooth tube end shapes will beobtained which are free from all rolling and spinning marks, as well ashammer impressions. Objectional vibrations are also eliminated due tothe absence of rapidly rotating eccentric rolls and reciprocatingswaging hammers.

A wide variety of tube end shapes may be produced with a single machine.The tools are relatively inexpensive and the machine is ef-- ficientlylaid out to accommodate the numerous forms of tools. Thus, a simple setof tools consisting of a punch, and a pair of clamp blocks may beemployed to produce work within commercial tolerances, or a moreelaborate self-contained set of tools can be built requiring noadjustments, to obtain a combination of shapes to fit exactingspecifications with one operation.

A safety feature of the machine is the emergency stop button, which,when depressed at any time during the operating cycle, causes themachine to reverse instantly, and open up the chucking dies so that thetube may be removed, whenever desired.

Essentially the machine is a versatile, doubleaction automatic hydraulicpress. It is doubleaction by reason of the fact that it operates boththe vertically-movable crosshead and the horizontally-movable formingram. It is automatic in that the pressing of the start push buttoncauses the machine to complete an entire cycle of operation within ashort time.

The chucking crosshead and the tool-carrying ram are both actuated bypistons located in hydraulic cylinders in which oil under pressure isforced by a motor-driven pump from an oil reservoir which is built intothe frame of the machine. The pump is operated from an independentcontrol box which starts and stops the motor. Hy-

draulic valves installed in the hydraulic circuit,

located at the rear of the machine, control the operating pressures ofthe system and the proper sequence of each phase of the cycle. All ofthese valves are accessible and easily adjusted.

By means of the present machine, numerous tube end shapes such as beads,single and doublelapped flares, single and double-lapped flanges,expanded and reduced sections, as well as com binations of the same, maybe readily formed on tubes of any workable metal or alloy.

In view of the fact that the present machine has only a few moving partsand that only the motor and pump bearings and the horizontal traverseslide require lubrication, long life can be expected therefrom.

Referring now to the drawings in which like reference numerals denotecorresponding parts throughout the several views, the numeral IDindicates the rectangular. frame of the machine, and the numeral lOa theupper portion thereof. The

4 frame H] is supported upon the fiOOr by means of four vertical legs,as shown.

In the forward part of the upper frame portion ltla, provision is madeof an upstanding end thrust lug H which is adapted to support a pair ofcomplementary cooperating bottom and top chucking dies |2, E3, theformer of which is seated on the frame portion |0a. Each of the chuckingdies |2, I3 is herein shown (Fig. 4) as being provided on one flathorizontal face with a plurality (three in this instance) ofsemi-circular die grooves l6, l1, l8, and on its opposite face with asingle semi-circular die groove IS. The die grooves l6, l1, |8, [9 areprovided with beveled edges 20, 2|, 22, 23, respectively, as shown. Theouter sides of both chucking dies 52, i 3 are provided with verticalrectangular slots 24, 25 which are adapted to absorb the end thrust ofthe forming ram and guide the movable chucking die in its up and downmovements in cooperation with apair of vertical ribs 25, 2'! formed on apair of .L-shaped brackets 28, 29 secured to the upper frame Illa.

The upper chucking die l3 is adapted to be raised and lowered into andout of clamped position by means of a pair of vertical draw bars 30, 3|,which are preferably round in cross section, and provided on their upperends with a pair of nuts 32, 33, respectively, which engage tightlyagainst a movable upper crosshead 38 which embraces said drawbars, andto which crosshead the upper movable chucking die is detachably securedas by screws 33a, 330. located in tapped holes 3317,3327.

Provision is also made of a lower crosshead 35 which is secured to thedrawbars 30, 3! by a pair of nuts 36, 31 located underneath said lowercrosshead 35. The crosshead 35 is adapted to be connected by means of achucking cylinder bolt 38, having a head 39 and a threaded lower end 48,to a tapped upper neck 4| of a chucking piston 42. which is adapted toreciprocate vertically within a chucking cylinder 43 supplied with lightoil under pressure from an oil reservoir 85, through a pair of ports 44,45.

By means of this construction, it will be seen that the chucking piston42 is adapted to be moved upwardly and downwardly, respectively, toclamp and unclamp the tube T between the chucking dies |2, |3.

After the tube T has been clamped tightly between the chucking dies 2,l3, by the mechanism described above, it is adapted to be headed,flared, flanged, expanded, sunk, double-la flared, double-lap flanged,etc. by means of a horizontal toolcarrying U-shaped plunger gate or ram25 which is adapted to slide within a pair of horizontal dovetailed ways46a, 46a mounted in the top of the frame section Illa.

The ram 46 has secured thereto at its forward end, as by screws 46b, apunch-holding block 48, which has a punch 49 detachably held thereinselectively, in any one of three horizontal sockets 50, by set screws41.

The ram 46 is provided with a forward rectangular recess 41a having apair of opposed intermediate vertical slots 5|, 52 for selectivelyreceiving a reducing (or sinking) die (Fig. 8), shaped to fit withinsaid slots 5|, 52 (see Fig. 8A), and having a pair of side flanges 54,55 (see Fig. 8), said side flanges being adapted to rest upon the topsurface of ram 48 at points adjacent said slots 5|, 52.

The recess 47a in the ram 45 is also provided with a rear cylindricalsocket 56 above which is a vertical aperture 51 for receiving a verticalset screw 51a which is adapted to engage a centering plug 59 of adetachable expanding punch 58 (as clearly shown in Fig. 9)-said plug 59fitting in said socket 55.

It will be understood that the end punch 49, the sinking die 53, and theexpanding punch 58 may be selectively employed, and in use may bedetacliably secured on the front of the ram 45, in the opposed recesses51, 52, and in the rear socket 556, respectively.

Embracing the rear end of the ram 46 is a U- shaped adaptor member fillhaving a vertical pivot pin passing therethrough, said pivot pin beingprovided with a knurled top head 82 for convenience in manipulation.

The adaptor member iii) is provided with a reduced rear threaded section63 which is adapted to be screwed into a ram-operating piston rod 66which is connected to a piston located within a horizontal workingcylinder 65 supplied with oil under pressure from the pump 8i! through apair of ports 66, 61.

In order to limit the inward movement of the tube T when it is beinginserted between the chucking dies l2, I3, provision is made of asubstantially vertically adjustable rectangular open bracket 58 having aforwardly-oflset horizontal bottom stop bar 69. The bracket 83 isprovided at its top with a forwardly inclined ear H! which is pivoted.on a horizontal pin ii, mounted in a pair of opposed pivot brackets l2,73 secured to a raised section of the upper crosshead 34, as clearlyshown in Figs. 6 and '7 of the drawing.

Provision is also made of a pair of rearwardlyextending coiled springsM, 75 located in a horizontal position in sockets on the rear of theupper cro shead 3 !said springs engaging intermediate sections of thevertical legs of the stop bracket 68, as shown.

In order to adjust the position of the bottom stop bar 59, provision ismade of a horizontal adjusting screw 76 having a forward threaded endlocated in a tapped hole 1'! on the rear of the upper crosshead 34, andbeing provided with a knurled rear head 18 for convenience inmanipulation.

The intermediate portion of the stop-adjusting screw is adapted to belocated within an elongated slot '19 formed in the bracket 68 below theforwardly inclined top ear 'H).

The numeral 8i! indicates a hydraulic pump which is adapted to be drivenby an electric motor 34 under the control of a motor starter 82, havinga pair of start and stop switch push buttons 33, EM, as clearly shown inFig. 1. 0'11 for operating the hydraulic system is stored in thereservoir 85. Provision is also made of a pair of relays 8%, 8? locatednear the lower portion of the frame I 0said relays being connected to afour-way valve 88, having a pair of solenoids 89, 95, as clearly shownin Fig. 2.

Provision is also made of a main relief valve iii and a secondary reliefvalve 92, arranged as shown in Fig. 2.

In order to continue the cycle of operation, automatically, after themachine has been started into operation by means of a start switchbutton 96, provision is made of a pressure switch 93, a counter-balancedvalve 94, and a sequence valve 95, as shown.

To permit the machine to be reversed whenever desired, an emergency stopswitch button 9'! is located adjacent the start button 95.

Operation In the operation of the machine herein disclosed, themotor-driven pump 88 will first force oil under pressure from thereservoir to the chucking cylinder 43 for depressing the upper chuckingdie it against the lower die 12, thereby lowering the stop bar 69 out ofthe path of the forming tool, and subsequently will deliver oil underpressure to the working cylinder 65 to force the punch-carrying ram 46forwardly toward the tube T.

The operating cycle of the machine is started by actuating the startpush button 96, which is located conveniently at the upper front portionof the machine. This causes the contacts of the relay -56 to close, andenergize one coil 89 of the solenoid-operated four-way valve 88. Oilunder pressure will then flow from the pump 80 through the main reliefvalve 9 I, the solenoid valve 88, the secondary relief valve 92, intothe chucking cylinder 43, causing the upper chucking die 13 to descendand clamp the tube '1', which has previously been inserted manuallythrough the end of the machine against the adjustable stop bar 69.

The oil pressure will then build up and cause the secondary relief valve532 to open, permitting oil to flow into the rear of the piston in themain working cylinder 55-5, and thus causing the ram 38 to carry theforming tool against the tube T.

When the tube T has been shaped by the forming tool carried by the ram,the pressure will build up still further and cause the pressure switch93 to close automatically and actuate the second relay 8'! which willreverse the position of the solenoid valve 88. Oil will then be admittedto the forward side of the piston in the working cylinder 65, and theram 46 will be caused to return to its original rear position.

It will be understood that during the rearward movement of thetool-carrying ram 46, the crossheads 34 and 35 will be held in the downposition by the counter-balance and sequence valves 95, 95.

When the ram returns to its original rear position, it will also beunderstood that the operation of the valves 94, 95 will admit oil to thechucking cylinder 43 causing the vertical crossheads 34, 35 to rise totheir original elevated positions.

The tube T may then be removed manually from the machine, which willthen be ready for another operating cycle.

If at any time it is desired to remove a defective tube, or stop themachine for any other reason, without the necessity of completing theentire cycle of operation, it will only be necessary to depress theemergency stop button 9?, causing the operating cycleto reverse itselfimmediately.

It will be understood that if desired, the system can be so regulatedthat only the crosshead will descend and rise, or that only the ram willreciprocate.

The relays 86, 81, are, of course, controlled by the push buttbns 96, 97and the automatic pressure switch .93. In other words, the actuation ofthe start button 95 will operate the relay 85, while the actuation ofthe stop button 91, or the automatic operation of the pressure switch93, will cause the other relay 81' to func-- tion.

One advantage of the present machine is that it is extremely easy tooperate, because it is merely necessary for the operator to sit or standin front of the machine and manually insert the tube T through anopening inside of the casing, until it engages the stop bracket 68. Itwill then only be necessary to operate the start push button 96,whereupon the upper chucking die [3 will close upon the tube T, and thesuccessive steps of the forming operation will thereafter be performedautomatically, including the retracting of the tool-carrying ram, andthe opening of the chucking dies, after which the tube T may be removedmanually by the operator.

A further advantage is that the stop bracket may be readily adjusted bythe manipulation of the control knob 18 on the end of the stop screw 16so as to control the outside diameter of the bead or the shape of theflare, flange, etc. formed on the tube end, with a high degree ofaccuracy.

A further advantage is that all moving parts of the machine may beenclosed by a protective casing (not shown), thereby making it entirelysafe for the operator.

A further advantage is that with the present machine it is possible toproduce a flare in which all waviness is eliminated.

A further advantage is that progressive operations may be performed withthe same machine by means of three sets of tools laid side by side (asshown in Fig. 4).

The present machine also makes it possible to produce a steep flare onthe end of a tube, and, if desired, mandrels may be used, which may ormay not be collapsible, and may or may not be used with strippers.

A further advantage of the present machine is that since the tube isarranged in a horizontal position, longer lengths may be handled thanwas possible with vertical crank-operated presses.

While there has been disclosed in this specification several forms inwhich the invention may be conveniently embodied, it is to be understoodthat these forms are shown for the purpose of illustration only, andthat the invention is not to be limited to the specific disclosures, butmay be modified and embodied in various other forms without departingfrom its spirit. In short, the invention includes all the modificationsand embodiments coming within the scope of the claims.

Having thus fully described the invention, what is claimed as new, andfor which it is desired to secure Letters Patent, is:

1. In a machine for automatically forming the end of a tube made of amaterial capable of being cold-worked. hydraulic means for chucking saidtube to hold it in stationary position, a punch for engaging the'end ofsaid tube, a hydraulically-operated punch-holding ram mounted toreciprocate in said machine, means for operating said chucking means toclamp said tube, means responsive to the completion of said chuckingoperation to automatically thereafter successively advance and retractsaid ram to force said punch into and out of engagement with the end ofsaid tube and open said chucking means, and stop means to limit theinserted position of the end of said tube prior to the closing of saidchucking means, said stop means being fixed upon said chucking means formovement therewith during clamping and uncla-mping movement thereof.

2. In a machine for forming the end of a tube made from a materialcapable of being coldworked, a frame, a stationary lower chucking diesecured to said frame, a hydraulically-operated downwardly movablecrosshead, an upper chucking die secured to said crosshead for clamping8 said tube against said stationary chucking die, a forming tool, a.hydraulically-operated ram having means for detachably holding saidtool, means responsive to the completion of the clamping of said tubefor automatically thereafter successively advancing and retracting saidram to force said tool into and out of forming engagement with the endof said tube and raising said upper chucking die, and stop means tolimit the inserted position of the end of said tube prior to the closingof said chucking dies, said stop means being fixed upon said upperchucking die for movement therewith during clamping and unclampingmovement thereof.

3. In a machine for forming the end of a tube made from a materialcapable of being coldworked, a frame, a stationary lower chucking diesecured to said frame, a hydraulically-operated downwardly movablecrosshead, an upper chucking die secured to said crosshead for clampingsaid tube against said stationary chucking die, a forming tool, ahydraulically-operated ram having means for detachably holding saidtool, means responsive to the completion of the clamping of said tubefor automatically forcing said upper die down upon said tube, andthereafter successively advancing and retracting said ram to force saidtool into and out of forming engagement with the end of said tube andraising said upper chucking die, and a rectangular open stop bracketpivoted to said crosshead above the position of said tube, said brackethaving a bottom stop bar initially in alignment with said tube to limitthe position thereof when it is being inserted through the chuckingdies, prior to the closing thereof, the downward movement of saidcrosshead during the closing of said chucking dies serving to move saidstop bar out of alignment with said tube and ram.

4. In a machine for forming the end of a tube made from a materialcapable of being coldworked, a frame, a stationary lower chucking diesecured to said frame, a hydraulically-operated downwardly movablecrosshead, an upper chucking die secured to said crosshead for clampingsaid tube against said stationary chucking die, a forming tool, ahydraulically-operated ram having means for detachably holding saidtool, means responsive to the completion of the clamping of said tubefor automatically forcing said upper die down upon said tube, andthereafter successively advancing and retracting said ram to force saidtool into and out of forming engagement with the end of said tube andraising said upper chucking die, and an open rectangular spring-pressedstop bracket pivotally connected to said crosshead to limit the positionof the end of said tube when it is inserted between said chucking diesprior to the closing thereof, whereby the operation of moving saidcrosshead downwardly will cause said stop block to move out of alignmentwith said tube and said ram.

5. In a machine for forming the end of a tube made from a materialcapable of being coldworked, a frame, a stationary lower chucking diesecured to said frame, a hydraulically-operated downwardly movablecrosshead, an upper chucking die secured to said crosshead for clampingsaid tube against said stationary chucking die, a forming tool, ahydraulically-operated ram having means for detachably holding saidtool, means responsive to the completion of the clamping of said tubefor automatically forcing said upper die down upon said tube, andthereafter successively advancing and retracting said ram to force saidtool into and out of forming engagement with the end of said tube andraising said upper chucking die, and said ram having an open rectangularrecess at the forward end thereof, means for detachably and selectivelysecuring to the end of said ram a punch for beading, flaring, orflanging the end of said tube, means on the opposite sides of said ramrecess for detachably and selectively securing a tool for reducing thediameter of the end portion of said tube, and means in the rear of saidram recess for detachably and selectively securing a tool for expandingthe diameter of the end portion of said tube.

6. In a machine for forming the end of a tube made from a materialcapable of being coldworked, a frame, a stationary lower chucking diesecured to said frame, a hydraulically-operated downwardly movablecrosshead, an upper chuck.- ing die secured. to said crosshead forclamping said tube against said stationary chuckin die, a

forming tool, a hydraulically-operated ram having means for detachablyholding said tool, means responsive to the completion of the clamping ofsaid tube for automatically forcing said upper die down upon said tube,and thereafter successively advancing and retracting said ram to forcesaid tool into and out of forming engagement with the end of said tubeand raising said upper chucking die, a U-shaped adaptor embracing therear of said ram, and a removable vertical pivot pin passing through thearms of said adaptor and said ram, said adaptor having a reducedthreaded rear end detachably connected to the hydraulic ram-operatingpiston. JOHN L. VAILL.

10 REFERENCES orrsn The following references are of record in the fileoi this patent:

UNITED STATES PATENTS Number Name Date 410,000 Matheson Aug. 29, 1889489,439 Vollmer et a1 Jan. 3, 1893 716,217 Glenn Dec. 16, 1902 774,154Budd Nov. 8, 1904 818,337 Barnes Apr. 17, 1906 989,805 Reynolds Apr. 18,1911 1,150,040 Kuhn Aug. 17, 1915 1,383,840 Mueller et a1 July 5, 19211,740,792 Strachauer Dec. 24, 1929 1,868,094 Devine July 19, 19321,914,235 Benbow June 13, 1933 1,950,154 Rosenberg Mar. 6, 19341,955,356 Brenner Apr. 17, 1934 2,023,657 Wilson Dec. 10, 1935 2,100,939Brenner Nov. 30, 1937 2,176,188 Poole Oct. 17, 1939 2,241,807 Cotner May13, 1941 2,299,105 Muir Oct. 20, 1942 2,301,028 Esch Nov. 3, 19422,302,115 Gazey Nov. 17, 1942 2,394,841 Bugg Feb. 12, 1946 2,438,999Hartley Apr. 6, 1948 FOREIGN PATENTS Number Country Date 565,662 GreatBritain Nov. 21, 1944

